Bill, here is a paper I wrote a while back:
Lock Tuning for Idiots (IOW me!)
Greetings, I was the lucky winner of one of the unmarked Charleville Locks on EBay. I thought somebody would outbid me, but nobody did, 1 more penny & it would have been yours!
Anyway, when I got the thing, it was quickly apparent that it wasn't remotely near a Jim Chambers lock. The flint would literally crash into the frizzen, open it 1/8-1/4" & then everything would stop, and worst of all, no sparks.
Over the last few years I have made Dixon's & listened to Keith Castille's seminar on lock tuning. My choices were a $100 boat anchor (& not a good anchor at that) or what the $#*!: try what Keith has been telling us to do for years: eliminate friction & scrubbing.
#1 was to strip the lock. Sure enough, the inside of the lock plate was "as cast". IOW rough & pebbly! Too much friction! I took sandpaper & files & got the inside of the lock as smooth as I could. I then polished it on my cheapo Sears polisher & had it shining like a new nickel.
#2 was the main spring. Three things needed doing: First, sand the spring on the belt sander so it would not "scrub" the lock plate, IOW you need to sand off just enough to see a "wee smidgen" of daylight between the spring & the plate. Two was to carefully round the toe of the spring where it rides on the tumbler and finally #3 was to polish the entire spring.
#3, the tumbler was next. It already had a small ridge on the plate side, so the whole thing wasn't riding on the plate, finally a break! I tried to put it back in the plate & it wouldn't go back in!! Holy smokes, talk about too much friction! Hmm, Keith didn't mention this problem, what to do? Well, I also went to Jim Chamber's seminar & he mentioned that he lathe turns his tumblers & reams his plates, so the fit is .001" or better. I don't have a lathe (Hint to Santa), but I do have an electric drill & emery cloth. I chucked up the tumbler in the drill, clamped the drill in the vise, cut a strip of emery cloth & went to it. Well not quite, I had to trim the emery strip 2 more times to get it small enough. After a minute or so it went into the plate, no problemo. I also polished the tumbler where the the toe of the mainspring rides.
#4 I didn't want to fool with the sear too much, so I rounded over the nose on the belt sander & polished it.
Time to test it out… I put the lock back together, but instead of using a 12 lb sledge to put the hammer back on the tumbler (like Gepetto did), I used a small hammer & a block of wood & made sure the hammer stood off from the lock plate just an ooch so it wouldn't scrub the lock plate. I found a new flint, positioned it correctly in the jaws & !@*%&@ if it didn't have a 15 lb trigger pull, I finally got it go off & darned if the flint didn't smash into the frizzen, throw 2 sparks & come to grinding halt part way down the frizzen.
Ok, time to go into scientific analytical mode. What hadn't I fooled with? The frizzen spring, maybe it was out of balance with the main spring, Keith had said something about that. Hmmmm, OK, how to test the theory? I remembered that Wallace Gusler used some funny words in "The Gunsmith Of Williamsburg" video, he said something like "the frizzen spring needs to be strong enough to keep the frizzen from flopping around". Not quite how Keith put it, but it got me to thinking. I took the frizzen spring off, set the cocked lock across the palm of my hand & with my thumb, I held the right side of the frizzen shut & with my middle finger, I held the left side of the frizzen shut. I applied just enough pressure with my fingers to keep the frizzen from "flopping around". I tripped the sear & holy sparks batman! I had everything I wanted: sparks to make Jim Chambers proud & and a fully opened frizzen.
OK, back to the belt sander & the bucket of water. I ground & I ground & I ground some more. I finally got the frizzen spring thin enough to where I could pinch it not quite halfway closed, maybe a 1/3. Back onto the lock & bingo, sparks & the frizzen fully open. But wait: now the frizzen flops around in the open position because the toe & heel of the frizzen no longer contact the top of the frizzen spring. Darn, I had ground off too much at the top of the spring where the toe rides. OK, I gave up on propane, mapp gas, little oxygen bottles & little mapp bottles; I got sick & tired of going to Home Depot every time I needed to get something hot, so I bought a full blown OxyAcetylene setup, I highly recommend it. I found my Brownells Heat Stop Paste, made a big ball of it around the bend of the spring & heated up the spring where the toe of the frizzen rides & put just a little hump in it. Success! The toe & heel of the frizzen stay in contact with the frizzen spring regardless of whether the frizzen is open or closed.
Cock the lock, close the frizzen, press on the sear, press on the sear, really press on the sear & finally good sparks & a fully open frizzen. What about the sear? Well looking at it, it was very apparent that it could double as a garage door spring, so I took it to the belt sander & gave it the frizzen spring treatment. I also rounded over the toe & polished it. Much better: a reasonable military trigger pull, sparks to beat the band & an open frizzen. IOW, I now had a real, usable lock.
I put a few drops of Ballistoll on the contact points tried it again & same as before: good sparks & an open frizzen. Since it's humid here in Houston, I sprayed the lock down with WD40 & decided to call it a day. But since it worked so well, I just had to try it one more time. Cock the hammer, close the frizzen, trip the sear & WHAT!!! 1 lousy spark!!! Not good. How could I go from good to bad in 5 seconds?? Back into the scientific analytical mode, could it be the WD40? I wiped the frizzen with a little mineral spirits & tried again, whew, big sigh of relief, my sparks were back.
Well that's my story on lock tuning. I found it well worth the effort & I have an even better appreciation for the work that Jim Chambers & all the lock makers put into a quality lock. Give it a try before you throw that lock into the junk drawer.
Rgds,
John